Method for preparing a densified insulation material for use in appliance insulated structure

ABSTRACT

A method for forming a vacuum insulated structure using a prepared core material includes preparing a powder insulation material defining a bulk density, pre-densifying the powder insulation material to form a pre-densified insulation base, crushing the pre-densified insulation base into granular core insulation to define a core density of the granular core insulation, disposing the granular core insulation having the core density into an insulating cavity defined within an insulating structure and expressing gas from the interior cavity of the insulating structure to further densify the granular core insulation to define a target density. The granular core insulation defines the target density disposed within the insulating structure defines the vacuum insulation structure, wherein the target density defines a density in the range of from approximately 80 grams per liter to approximately 350 grams per liter.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a divisional of U.S. patent application Ser.No. 17/361,907 filed Jun. 29, 2021, entitled METHOD FOR PREPARING ADENSIFIED INSULATION MATERIAL FOR USE IN APPLIANCE INSULATED STRUCTURE,which is a continuation of U.S. patent application Ser. No. 14/961,934filed Dec. 8, 2015, entitled METHOD FOR PREPARING A DENSIFIED INSULATIONMATERIAL FOR USE IN APPLIANCE INSULATED STRUCTURE, now U.S. Pat. No.11,052,579, the entire disclosures of which are hereby incorporatedherein by reference.

BACKGROUND

The device is in the field of insulating materials, specifically,insulating materials that can be densified for use in insulatingstructures for household appliances.

SUMMARY

In at least one aspect, a method for forming a vacuum insulatedstructure using a prepared core material includes preparing a powderinsulation material defining a bulk density, pre-densifying the powderinsulation material to form a pre-densified insulation base and crushingthe pre-densified insulation base into granular core insulation todefine a core density of the granular core insulation. The granular coreinsulation having the core density is then disposed into an insulatingcavity defined within an insulating structure. Gas is expressed from theinterior cavity of the insulating structure to further densify thegranular core insulation to define a target density. The granular coreinsulation defines the target density disposed within the insulatingstructure that defines the vacuum insulation structure, wherein thetarget density defines a density in the range of from approximately 80grams per liter to approximately 350 grams per liter.

In at least another aspect, a method for forming a vacuum insulatedappliance cabinet using a prepared core material includes preparing apowder insulation material defining a bulk density, pre-densifying thepowder insulation material to form a pre-densified insulation base andcrushing the pre-densified insulation base into granular core insulationto define a core density of the granular core insulation. An appliancestructure is provided having an outer wrapper and an inner liner, theouter wrapper and inner liner defining an insulating cavitytherebetween. The granular core insulation having the core density isdisposed into the insulating cavity. The insulating cavity of theappliance structure is sealed to contain the granular core insulationtherein and expressing at least a portion of the gas is expressed fromwithin the insulating cavity to form a vacuum insulated structure.

In at least another aspect, a method of preparing a core material forinstallation into an insulated structure includes blending a pluralityof insulating components to form a powder insulation material having abulk density, wherein the insulating components include at least one ofsilica, aerogel, glass fibers, and glass spheres. The powder insulationmaterial is pre-densified to form a pre-densified insulation base andthe pre-densified insulation base is then crushed to define a granularcore insulation having a core density, wherein the core density isdifferent than the bulk density and the core density is in the range offrom approximately 80 grams per liter to approximately 350 grams perliter.

These and other features, advantages, and objects of the present devicewill be further understood and appreciated by those skilled in the artupon studying the following specification, claims, and appendeddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a front perspective view of a refrigerating applianceincorporating an aspect of the granular core insulation disposed withinan insulating structure of the appliance;

FIG. 2 is a schematic flow diagram illustrating an exemplary process forforming an aspect of the granular core insulation;

FIG. 3 is a top perspective view of an exemplary form of a pre-densifiedinsulation base achieved after conducting a pre-densifying step of anexemplary process for forming the granular core insulation;

FIG. 4 is a perspective view of a crushed form of the precompactedinsulation base of FIG. 3 ;

FIG. 5 is a schematic diagram illustrating an exemplary mechanism forperforming an aspect for a method for forming the granular coreinsulation and forming an insulating structure for an appliance;

FIG. 6 is a schematic flow diagram illustrating a method for forming avacuum insulated structure using a prepared core material;

FIG. 7 is a schematic flow diagram illustrating an aspect of a methodfor forming a vacuum insulated appliance cabinet using a prepared corematerial; and

FIG. 8 is a schematic flow diagram illustrating an aspect of a methodfor preparing a core insulation material for installation into aninsulated structure.

DETAILED DESCRIPTION OF EMBODIMENTS

For purposes of description herein the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the device as oriented in FIG. 1 . However, itis to be understood that the device may assume various alternativeorientations and step sequences, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of theinventive concepts defined in the appended claims. Hence, specificdimensions and other physical characteristics relating to theembodiments disclosed herein are not to be considered as limiting,unless the claims expressly state otherwise.

As illustrated in FIGS. 1-5 , reference numeral 10 generally refers to avacuum insulated structure that is disposed within an appliance 12, suchas a refrigerator, freezer, dishwasher, water heater, laundry appliance,oven, or other similar appliance or fixture that requires thermal and/oracoustical insulation within an insulated structure 14. Disposed withinthe insulated structure 14 is a granular core insulation 16 thatincludes a densified form of a powder insulation material 18. Thegranular core insulation 16 can be disposed directly into the insulatingstructure for the appliance 12, such as within an insulating cavity 20defined between an outer wrapper 22 and an inner liner 24 of theappliance 12. Alternatively, the granular core insulation 16 can beinstalled within an insulating panel that is then installed as a panelmember 26 within the insulating cavity 20 of the insulating structure ofthe appliance 12.

According to the various embodiments, as exemplified in FIGS. 1-5 , thegranular core insulation 16 can be prepared, according to at least oneaspect, by placing a base insulation 28 into a blending apparatus 30 andcombining the base insulation 28 with various additives 32 that caninclude, but are not limited to, various opacifiers such as carbonblack, silicon carbides, titanium oxides, reinforcing materials, such asorganic/inorganic fibers and organic/inorganic insulating spheres. Thebase insulation 28 can include various materials that can include, butare not limited to, fumed silica, precipitated silica, aerogel nanopowder, silica fume, inorganic microspheres, organic microspheres,pearlite, rice husk ash, diatomaceous earth and combinations thereof,and other similar powder materials suitable for vacuum insulationstructures. The blending apparatus 30 combines these various materialsto form the powder insulation material 18 having a bulk density 34. Itis contemplated that the powder insulation material 18 can be anano-porous silica blend micro agglomerate having particle agglomeratesizes that are approximately 1 micron, although other larger and smalleragglomerate sizes are contemplated. The bulk density 34 of the powderinsulation material 18 can be within the range of approximately 30grams/liter to approximately 150 grams/liter. It is contemplated thatgreater and lesser bulk densities can be achieved depending upon thebase insulation 28 and additives 32 included within the blendingapparatus 30 to form the powder insulation material 18. The degree ofblending, the types of additives 32, types of base insulation 28, andother factors can cause variations in the density of the powderinsulation material 18.

Referring again to FIGS. 2-5 , undensified silica materials and the oneor more opacifiers, and other blend materials, are included within theblending apparatus 30. It is contemplated that where an opacifier isused, the opacifier within the powder insulation material 18 can be fromapproximately 5% to approximately 40% of the total weight of thematerial disposed within the blending apparatus 30. The opacifier isadded to reduce radiation conduction of the silica mix. This reductioncan be within the range of approximately 0.5 mw/mk to 2.0 mw/mk. It iscontemplated that the blending apparatus 30 for performing the blendingand/or mixing may or may not include an intensifier 40. The intensifier40 can take various forms that can include various supplemental mixingmechanisms, injectors, combinations thereof, or other similarsupplemental mechanisms that intensify the blending/mixing operations ofthe blending apparatus 30. An exemplary blending apparatus 30 caninclude a Hosokawa Vrieco-Nauta® with an intensifier 40 or anycommercially available high shear mixer such as a V-block tubing mixer,a Ross mixer or similar mixer can be used to prepare this blend.Regardless of the blending apparatus 30 used, the blending apparatus 30can be run for varying periods of time, where the blending time candepend upon the mixture volume, the various additives 32 included withinthe powder insulation material 18, and other factors.

Referring again to FIGS. 2-5 , in order to achieve the proper density ofthe granular core insulation 16, the undensified powder insulationmaterial 18 is first compacted by varying means into flakes or blanks orother densified or compacted particles of a pre-densified insulationbase 42. These compacted flakes or blanks that form the pre-densified orcompacted insulation base 42 have a density greater than that of thegranular core insulation 16 that will be disposed within the insulatedstructure 14. This pre-densifying process can be accomplished by variouscompacting mechanisms 44, one such exemplary compacting mechanism 44being a roller compactor 46 such as an APC L 200-50 from Hosokawa. It iscontemplated that other compacting mechanisms 44 can be used to performthe pre-densifying steps of the various methods for forming the granularcore insulation 16, such as vacuum compactors, presses, and others.Where a roller compactor 46 is used, the compactor may include a seriesof rollers 48 that serve to compact and densify the powder insulationmaterial 18 between the rollers 48 into the blanks or flakes of thepre-densified insulation base 42 (exemplified in FIG. 3 ). It iscontemplated, according to various aspects of the device, that duringthe compaction process, the powder insulation material 18 is conveyedinto a roller gap of the roller compactor 46 by a cylindrical feedingauger 50 having a conical feed zone 52. Higher yield through the auger50 can be achieved by including a vacuum de-aeration system within thefeeding auger 50. The vacuum de-aeration system may be used at a base ofthe auger 50 or along the sides of the housing extending around theauger 50. In various embodiments, a lining can be placed on the sidesproximate auger 50. Such lining can include a filter media, which may bemade of various materials that include, but are not limited to, paper,synthetic material, composite or metal. It is contemplated that the useof the vacuum assist feature of the de-aeration system can serve toincrease the compressive strength of the compacted/densified material.

Referring again to FIGS. 2-5 , it is contemplated that delivery of thepowder insulation material 18 from the blending apparatus 30 to thecompacting mechanism 44 can be performed by various delivery systems 60that can include, but are not limited to, a pumping system, a pneumaticor vacuum conveying system, belt systems, gravity fed systems, flexiblescrew conveying systems, combinations thereof, and other materialdelivery systems 60 that can deliver the powder insulation material 18having a very minimal density.

Referring again to FIGS. 2-5 , the pre-densified insulation base 42formed through the compacting mechanism 44 can be delivered to acrushing apparatus 70 for conversion into an aspect of the granular coreinsulation 16. Various pressing forces can be applied to thepre-densified insulation base 42 to arrive at a granular core insulation16 having various densities. By way of example, and not limitation, ithas been found that a pressing force of 18 kN results in a core density72 of the granular core insulation 16 of approximately 173 grams/liter.By reducing this pressing force, or by increasing the speed of the rollsthrough the crushing apparatus 70, granules 78 of different core density72 can be achieved. Such core densities 72 can include ranges fromapproximately 80 grams/liter to 350 grams/liter. It is contemplated thatdepending upon the desired density of the granular core insulation 16,greater or lesser core densities 72 can be achieved by varying thepressing force from the crushing apparatus 70 or the speed at which thematerial moves through the crushing apparatus 70.

According to various embodiments, various other mechanisms can be usedin conjunction with, or instead of, the crushing apparatus 70 totransform the pre-densified insulation base 42 into the granular coreinsulation 16. Such mechanisms and processes can include grinders,blenders, mixers, mills, flake crushers, combinations thereof, and othersimilar mechanisms that can at least partially break down thepre-densified insulation base 42.

According to the various embodiments, after the material for thegranular core insulation 16 is generated through operation of thecrushing apparatus 70, each granule 78 of the granular core insulation16 can be coated by one or more binders 80 that can serve to increasethe compressive strength of each granule 78. Such binders 80 caninclude, but are not limited to, binders that include various cellulose,wax, polyethylene glycol, gelatin, starch, polyvinyl alcohol,polymethacrylates, graphites, sodium silicates, various other organicand/or inorganic materials, and other similar materials that can serveto increase the compressive strength of each granule 78 of the granularcore insulation 16. The use of the binders 80 can serve to preventdeflection of the walls 82 of the insulated structure 14 during variouscompacting and/or gas expressing operations. The maximum size of theindividual granules 78 for the granular core insulation 16 can becontrolled by the inclusion of a screen having a particular mesh sizewithin or proximate the crushing apparatus 70, or by controlling thedistance between the mills. Through the various aspects of the processesdisclosed herein, granule 78 sizes between 300 nm to 5 mm can beachieved. The granules 78 on the higher size range can have increasedcompressive strength that can also add to the overall compressivestrength of the granular core material 16. The various aspects of theprocess disclosed herein may produce certain fines orundensified/uncompacted material that was not densified into a granularform. This material can be captured and disposed back into a hopper orthe blending apparatus 30 to be processed again.

Referring again to FIGS. 1-5 , in forming the granular core insulation16, it is contemplated that certain additives 32 can be included withinthe granular core insulation 16 to vary the density, and also modify theinsulating properties of the granular core insulation 16. Such additives32 can include, but are not limited to, insulating gas 90, such asargon, neon, carbon dioxde, xenon, krypton, combinations thereof, andother similar insulating gasses, insulating glass spheres, such asmicrospheres, nanospheres, hollow spheres, and other forms of insulatingorganic/inorganic spheres, additional powdered insulation material andother insulating materials. It is contemplated that the additives 32 canbe included within the granular core insulation 16 such that aninsulating material occupies substantially all of the space within theinsulating cavity 20 of the insulated structure 14 when the granularcore insulation 16, and the additives 32 are included within theinsulating cavity 20 of the insulated structure 14. To assist with thedeposition of the granular core insulation 16 and the various additives32 within the insulated structure 14, various vibrating mechanisms 92can be implemented to position the various materials in a packedconfiguration with minimal spaces between particles. Such a vibratingmechanism 92 can be a vibration table that vibrates the entire insulatedstructure 14. It is contemplated that vibration with low frequency andhigh impact may yield higher efficiency or better packing of thegranular core material 16 within the insulating cavity 20. Moreefficient packing can serve to increase the compressive strength of thegranular core material 16. Alternatively, the vibrating mechanism 92 canbe an apparatus that is temporarily placed within the insulating cavity20 to directly vibrate the various particles of the granular coreinsulation 16 and the various additives 32.

Referring again to FIGS. 2-5 , once the granular core insulation 16 isprepared, it may be necessary to dry the granular core insulation 16before being disposed within an insulated structure 14 or before beingtransported to another location for use in any one of variousapplications. When the granular core insulation 16 is dried and preparedfor installation into the insulated structure 14, the granular coreinsulation 16 can be directly fed into the insulating cavity 20 of theinsulated structure 14. By way of example, and not limitation, thegranular core insulation 16 can be fed directly into the insulatingspace defined between an inner liner 24 and an outer wrapper 22 of aninsulated structure 14 for an appliance 12. Alternatively, the granularcore insulation 16 can be disposed within the insulating cavity 20 of apanel member 26, such that the granular core insulation 16 within thepanel member 26 can be formed into a vacuum insulation panel that canbe, in turn, installed within the insulating cavity 20 of the insulationstructure of an appliance 12. Disposing techniques such as a doublediaphragm powder pump, an auger feed, and a flexible screw conveyor canalso be used.

Referring now to FIGS. 2-6 , having described the process for formingthe granular core insulation 16, a method 400 is now disclosed forforming a vacuum insulated structure 10 using a prepared core material,such as the granular core insulation 16. According to the method 400, apowdered insulation material defining a bulk density 34 is prepared. Asdiscussed above, preparation of the powder insulation material 18 can bethrough the use of a blending apparatus 30, where the powder insulationmaterial 18 includes various insulating materials that can include, butare not limited to, various silica powder, aerogel powder,organic/inorganic fibers, and organic/inorganic micro-nano spheres,pearlite, rice husk ash, diatomaceous earth, and other similar powdertype insulation materials (step 402). Once the powder insulationmaterial 18 is prepared, the powder insulation material 18 ispre-densified/compacted to form a pre-densified insulation base 42 (step404). The pre-densifying step can be accomplished by various compactingoperations, such as by a roller compactor 46 or a briquetting machine,vacuum packing, mechanical pressing, or other apparatus that can providea compressive force against the powder insulation material 18 to formthe pre-densified insulation base 42. After forming the pre-densifiedinsulation base 42, the pre-densified/compacted insulation base 42 iscrushed into the granular core insulation 16 to define a core density 72of the granular core insulation 16 (step 406).

According to the various embodiments, the various densifying andpre-densifying steps of the methods disclosed herein can take the formof any one or more processes through which the base insulation 28 isprocessed into the granular core insulation 16. Such densificationprocesses can include compaction, pressing, rolling, or other similarapplication of a positive compressive force. It is also contemplatedthat the densification of the base insulation 28 into the granular coreinsulation 16 can be accomplished through the extraction of gas, vacuumpacking, or other similar application of a negative compressive force.Combinations of the positive and negative compressive forces can also beimplemented to form the pre-densified insulation base 42 and/or thegranular core insulation 16.

According to the various embodiments, the core density 72 can be lessthan a target density 100 of the granular core insulation 16. It iscontemplated that the core density 72 of the granular core insulation 16can be provided such that further and finite densification of thegranular core insulation 16 can take place during subsequent steps ofthe process of forming the vacuum insulated structure 10.

Once the granular core insulation 16 having the core density 72 isprepared, the granular core insulation 16 is disposed within aninsulating cavity 20 defined within an insulated structure 14 (step408). As discussed above, the insulated structure 14 can be aninsulating structure for an appliance cabinet made from an inner liner24 and an outer wrapper 22. The insulated structure 14 can also be apanel member 26 that can be used to form a vacuum insulated panel 110for separate installation within the insulating cavity 20 of theinsulated structure 14 for the appliance 12 (step 408). It iscontemplated that once the granular core insulation 16 is disposedwithin the insulating cavity 20, gas 114 can be expressed from theinterior cavity of the insulated structure 14 to form the vacuuminsulated structure 10 (step 410). As discussed above, furtherdensification of the granular core insulation 16 can occur as gas 114 isbeing expressed from the interior cavity. In this manner, the granularcore insulation 16 having the core density 72, can be further densifiedinto the target density 100 of the granular core insulation 16.

According to the various embodiments, it is contemplated that as gas 114from within the insulating cavity 20 is expressed, an insulating gas 90can be injected into the interior cavity, such that the insulating gas90 replaces air or some other gas 114 having lesser insulatingcharacteristics than the insulating gas 90. Where the insulating gas 90is injected as the lesser insulating gas 90 is being expressed, it iscontemplated that the expression of gas 114 from the interior cavity maynot result in further densification of the granular core insulation 16.In such an embodiment, it is contemplated that the crushing step 406 ofthe pre-densified insulation base 42 into the granular core insulation16 can result in the core density 72 being substantially similar to thetarget density 100 desired for the design of the insulated structure 14of the appliance 12.

Referring again to FIGS. 2-5 , it is contemplated that the insulatedstructure 14 can include the interior insulating cavity 20 and can alsoinclude an insulation inlet 130 and a vacuum outlet 132. In such anembodiment, the insulation inlet 130 can be used to dispose the granularcore insulation 16, as well as various additives 32, within the interiorinsulating cavity 20 of the insulated structure 14. Once the properamount of granular core insulation 16 and additives 32 are installedtherein, the insulation inlet 130 can be sealed. The vacuum outlet 132of the insulated structure 14 can be used, as discussed above, toexpress gas 114 from the interior cavity of an insulated structure 14.The gas inlet 134 can also be included where the gas inlet 134 providesa conduit through which the insulating gas 90 can be injected as thelesser insulating gas 90 is expressed. Once the various gasinjecting/gas expressing steps are completed, each of the gas inlet 134and vacuum outlet 132 are sealed, thereby hermetically sealing theinsulated structure 14 to prevent the dissipation or other loss ofinsulating gas 90.

Referring now to FIGS. 2-5 and 7 , a method 600 is also disclosed forforming an insulated structure 14 in the form of a vacuum insulatedcabinet using a prepared core material such as the granular coreinsulation 16. According to the method 600, the base insulation 28,typically a powder, is prepared, substantially as described above, tocreate the powder insulation material 18 having the bulk density 34(step 602). The powder insulation material 18 is then pre-densified toform the pre-densified insulation base 42 (step 604). The pre-densifiedinsulation base 42 is then crushed into the granular core insulation 16to define either the core density 72 or the target density 100 for thegranular core insulation 16 (step 606). As discussed above, the coredensity 72 of the granular core insulation 16 may be less than thetarget density 100 of the granular core insulation 16 where furtherdensifying steps may be performed upon the granular core insulation 16before the vacuum insulated structure 10 is completed. Such furtherdensifying steps, as discussed above, can include, but are not limitedto, compressing the granular core insulation 16 through the expressionof gas 114 from the interior cavity, further physical compression of thegranular core insulation 16 and/or placing of additives 32 within thegranular core insulation 16. Where additives 32 are used, the additives32 can include, but are not limited to, organic/inorganic hollowspheres, pearlite, rice husk ash, diatomaceous earth with binders andopacifiers, insulating gas 90, glass fiber, additional powder insulationmaterial 18 in an uncompacted form, or other similar insulationmaterial.

Referring again to FIGS. 2-5 and 7 , according to the method 600, aninsulating appliance structure of an appliance 12 made from an outerwrapper 22 and an inner liner 24 can be provided (step 608). The outerwrapper 22 and inner liner 24 are sealed together to define aninsulating cavity 20 therebetween. The granular core insulation 16having either the core density 72 or the target density 100 is thendisposed into the insulating cavity 20 of the appliance structure (step610). The insulating cavity 20 is then sealed at the insulation inlet130 such that only gas 114 can be injected into or removed from theinsulating cavity 20 via the vacuum inlet and/or vacuum outlet 132 (step612). After the proper amount of granular core insulation 16 is disposedwithin the insulating cavity 20, at least a portion of the gas 114 isexpressed from within the insulating cavity 20 to form a vacuuminsulated structure 10 (step 614). As discussed above, as gas 114 isexpressed from the insulating cavity 20, insulating gas 90 can beinjected into the insulating cavity 20 such that the insulating gas 90replaces the gas 114 being expressed. Sealing of the insulating cavity20 is necessary as the insulating gas 90 will disperse, dissipate, orotherwise escape, from the insulating cavity 20 to the atmospherethrough any unsealed portion of the insulated structure 14.

According to the various embodiments, the granular core insulation 16can include one or more binders 80 to increase the compressive strengthof each granule 78 of the granular core insulation 16. The increasedcompressive strength of each granule 78 can serve to prevent deflectionof the outer wrapper 22 and/or the inner liner 24 during compression ofthe granular core insulation 16 and/or as gas 114 is being expressedfrom the insulating cavity 20 during formation of the vacuum insulatedstructure 10. The increased compressive strength of the granular coreinsulation 16, at least partially, withstands the inward deflection ofthe outer wrapper 22 and inner liner 24 to maintain a substantiallyconsistent thickness of the insulating cavity 20 of the vacuum insulatedstructure 10.

According to the various embodiments, the inner liner 24 and outerwrapper 22 of the appliance structure can be made of various rigidmaterials that can form a hermetic seal when attached together.Typically, both the inner liner 24 and outer wrapper 22 will be made ofthe same material, such as both being metal, both being a high barrierpolymer-type material, or other similar material that can behermetically sealed together. It is also contemplated, that in variousembodiments, the outer wrapper 22 can be metal and the inner liner 24can be plastic, or vice versa, or the outer wrapper 22 and inner liner24 can be made of various other similar or differing materials that canbe hermetically sealed together to form the vacuum insulated structure10.

Referring now to FIGS. 2-5 and 8 , a method 800 is disclosed forpreparing a core insulation material for installation into an insulatedstructure 14. According to the method 800, a plurality of insulatingcomponents are blended to form a powder insulation material 18 having abulk density 34 (step 802). As discussed above, these insulatingcomponents can include at least one of silica powder, aerogel powder,organic/inorganic fibers, and organic/inorganic micro-nano spheres,pearlite, rice husk ash, diatomaceous earth with opacifiers like carbonblack and silicon carbide as well as with some binders that includevarious cellulose, wax, polyethylene glycol, gelatin, starch, polyvinylalcohol, polymethacrylates and other organic materials as well asinorganic material such as sodium silicates. The powder insulationmaterial 18 is then pre-densified to form a pre-densified insulationbase 42 (step 804). The pre-densified insulation base 42 is then crushedto define a granular core insulation 16 having a core density 72, wherethe core density 72 is more dense than the bulk density 34 (step 806).

According to the various aspects of the methods disclosed herein, it iscontemplated that an insulating gas carrier 90 can be used to assist inthe movement of the base insulation 28 through the blending apparatus30, the delivery system 60, the compacting mechanism 44 and/or thecrushing apparatus 70. In such an embodiment, it is further contemplatedthat at least the blending apparatus 30, compacting mechanism 44 and thecrushing apparatus 70 can be housed within a closed system. This closedsystem can include various inlet and outlet valves through which gas 114and insulating gas 90 can be injected and/or expressed. Through the useof insulating gasses 90, the base insulation 28, and ultimately thegranular core insulation 16 can be delivered from the closed system ofthe blending apparatus 30, compacting mechanism 44 and the crushingapparatus 70 into the insulating cavity 20 of the insulated structure14. The transport of the granular core insulation 16 into the insulatingcavity 20 is assisted by the flow of the insulating gas 90 and theinsulating gas 90 is thereby delivered into the insulating cavity 20 toact as an additional insulating material. The insulating gas 90 caninclude, but is not limited to, argon, krypton, neon, carbon dioxide,xenon, combinations thereof and other insulating gasses 90.

According to the various embodiments, it is contemplated that thegranular core insulation 16 can then be installed within an insulatedstructure 14, such as an appliance cabinet, vacuum insulating panel, orother similar insulating structure. It is also contemplated that thegranular core insulation 16 can then be packaged for shipment to otherlocations for use in varying applications.

According to the various embodiments, it is contemplated that thegranular core insulation 16 can be used during the manufacture ofvarious fixtures and/or appliances 12 requiring at least someinsulation. Such appliances 12 can include, but are not limited to,water heaters, ductwork, fluid piping, household wall/roof insulation,vehicle insulation, insulation for various household and commercialappliances, and other similar applications. Typically, the granular coreinsulation 16 will be used for household appliances that can include,but are not limited to, refrigerators, freezers, dishwashers, laundryappliances, ovens, water heaters and other similar household appliances.Additionally, it is contemplated that the granular core insulation 16can be directly installed within the insulating cavity 20 for anappliance cabinet without using additional barrier films, vaporbarriers, or other sealing mechanisms. In such an embodiment, thegranular core insulation 16 is installed directly within the insulatingcavity 20 defined between the outer wrapper 22 and inner liner 24 of theinsulating structure for the appliance 12. It is also contemplated thatthe granular core insulation 16 can be fed into a flexible vacuumenvelope or bag to make a two-dimensional or three-dimensional vacuuminsulated panel 110 that can be later installed within the insulatedstructure 14 for the appliance 12. It is also contemplated that theinsulated structures 14 for appliances 12 can include structures for thecabinet, doors, door panels, drawers, and other components of theappliance 12.

It will be understood by one having ordinary skill in the art thatconstruction of the described device and other components is not limitedto any specific material. Other exemplary embodiments of the devicedisclosed herein may be formed from a wide variety of materials, unlessdescribed otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the device as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present device. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present device, and further it is to be understoodthat such concepts are intended to be covered by the following claimsunless these claims by their language expressly state otherwise.

The above description is considered that of the illustrated embodimentsonly. Modifications of the device will occur to those skilled in the artand to those who make or use the device. Therefore, it is understoodthat the embodiments shown in the drawings and described above is merelyfor illustrative purposes and not intended to limit the scope of thedevice, which is defined by the following claims as interpretedaccording to the principles of patent law, including the Doctrine ofEquivalents.

What is claimed is:
 1. A method for forming a vacuum insulated appliancecabinet using a prepared core material, the method comprising steps of:roller compacting a pre-densified insulation base; roller crushing thepre-densified insulation base into adhered granules of a core insulationmaterial to define a core density of the core insulation material,wherein the pre-densified insulation base and the core insulationmaterial includes powder insulating particles that are adhered togetherduring the preparing and crushing steps; disposing the core insulationmaterial into a cavity of an insulating structure having an outerwrapper and an inner liner; disposing an insulating gas into the cavity;sealing the cavity of the insulating structure to contain the coreinsulation material therein; and expressing at least a portion of theinsulating gas from within the insulating structure to form a vacuuminsulated structure.
 2. The method of claim 1, wherein the core densityof the core insulation material is equivalent to a target density forthe vacuum insulated structure, wherein the step of expressing at leasta portion of the insulating gas is substantially free of compression ofthe core insulation material.
 3. The method of claim 1, wherein the stepof expressing at least a portion of the insulating gas further densifiesthe core insulation material to be compressed from the core density to atarget density, wherein the target density is different than the coredensity.
 4. The method of claim 1, wherein the outer wrapper is metal.5. The method of claim 1, wherein the pre-densified insulation base is amixture of a plurality of insulating components, where the insulatingcomponents include at least one of silica powder, aerogel powder,insulating fibers, insulating spheres, perlite, rice husk ash,diatomaceous earth and an opacifier.
 6. The method of claim 1, whereinthe pre-densified insulation base is combined in a blending operation ina blending apparatus having an intensifier mechanism for performing theblending operation.
 7. The method of claim 1, wherein the insulatingstructure includes the cavity and an insulation inlet and a vacuumoutlet, the insulation inlet and the vacuum outlet definingcommunication between the cavity and an exterior of the insulatingstructure.
 8. The method of claim 3, wherein the insulating gas includesat least one of argon, neon, carbon dioxide, xenon, and krypton.
 9. Themethod of claim 3, wherein the target density defines a density in arange of from approximately 80 grams per liter to approximately 350grams per liter.
 10. A method of preparing a core material forinstallation into an insulated structure, the method comprising stepsof: blending a plurality of insulating components to form a powderinsulation material having a bulk density, wherein the insulatingcomponents include at least one of silica powder, aerogel powder,insulating fibers, insulating spheres, perlite, rice husk ash,diatomaceous earth and at least one opacifier; pre-densifying the powderinsulation material using a roller compactor to form a pre-densifiedinsulation base; crushing the pre-densified insulation base using aseparate roller compactor to further densify the powder insulationmaterial and to define adhered granules of a granular core insulationhaving a core density, wherein the adhered granules are adheredparticles of the powder insulation material; and coating the adheredgranules of the granular core insulation with a binder to increase acompressive strength of the adhered granules and to define the granularcore insulation to be a flowable material.
 11. The method of claim 10,wherein the bulk density is defined by a density within a range of fromapproximately 30 grams per liter to approximately 150 grams per liter.12. The method of claim 11, wherein the core density defines a densityin a range of from approximately 80 grams per liter to approximately 350grams per liter.
 13. The method of claim 10, wherein the binder used incoating the adhered granules includes at least one of cellulose, wax,polyethylene glycol, gelatin, starch, polyvinyl alcohol,polymethacrylate, graphite and sodium silicate.
 14. The method of claim10, wherein the granular core insulation is mixed with an additive,wherein the additive includes at least one of insulating glass spheresand additional amounts of the powder insulation material, pearlite, ricehusk ash, diatomaceous earth, at least one binder, at least oneopacifier and glass fiber.
 15. The method of claim 10, wherein thepre-densified insulation base is combined in a blending operation in ablending apparatus having an intensifier mechanism for performing theblending operation.
 16. A method of preparing a core material forinstallation into an insulated structure, the method comprising stepsof: blending a plurality of insulating components to form a powderinsulation material having a bulk density, wherein the insulatingcomponents include at least one of silica powder, aerogel powder,insulating fibers, insulating spheres, perlite, rice husk ash,diatomaceous earth and at least one opacifier; pre-densifying the powderinsulation material using a roller compactor to form a pre-densifiedinsulation base; crushing the pre-densified insulation base using aseparate roller compactor to further densify the powder insulationmaterial and to define adhered granules of a granular core insulationhaving a core density, wherein the adhered granules are adheredparticles of the powder insulation material; and coating the adheredgranules of the granular core insulation with a binder to increase acompressive strength of the adhered granules and to define the granularcore insulation to be a flowable material; disposing the granular coreinsulation into a cavity of an insulating structure having an outerwrapper and an inner liner; and sealing the cavity of the insulatingstructure to contain the granular core insulation therein.
 17. Themethod of claim 16, further comprising the step of: expressing gas fromwithin the insulating structure to form a vacuum insulated structure.18. The method of claim 16, further comprising the step of: disposing anadditive within the cavity of the insulating structure, wherein theadditive includes an insulating gas.
 19. The method of claim 18, whereinthe insulating gas includes at least one of argon, neon, carbon dioxide,xenon, and krypton.
 20. The method of claim 16, wherein the core densityof the granular core insulation is equivalent to a target density for avacuum insulated structure, wherein the step of expressing gas issubstantially free of compression of the granular core insulation, andwherein the step of expressing gas further densifies the granular coreinsulation to be compressed from the core density to a target density,wherein the target density is different than the core density.